Artificial stone flag

ABSTRACT

An artificial stone flag is constructed having an artificial stone flag body molded from the mixture of polyester/acrylic resin, densified alumina, catalyst, and hardening agent, and a flexible stuffing material embedded in the artificial stone flag body.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates to stone flags and, more particularly, to an artificial stone flag, which is acid proof, alkali proof, fire proof, waterproof, stain-free, easy to clean, and durable in use.

[0003] 2. Description of the Related Art

[0004] Regular artificial stone material (solid surface material) is generally made of polyester/acrylic resin added with densified alumina, catalyst and hardening agent. Catalyst catalyses hardening agent to harden polyester/acrylic resin. Densified alumina enhances the hardness and waterproof power of the finished product. Artificial stone material (solid surface material) made according to this method provides numerous advantages including (a) acid and alkali proof; (b) fire and waterproof; (c) non-capillary, stain-free, easy to clean; (d) durable in use. However, this design of artificial stone material (solid surface material) still has numerous drawbacks including (a) heavy and fragile; (b) deformable when constantly vertically compressed; (C) expensive.

SUMMARY OF THE INVENTION

[0005] The present invention has been accomplished under the circumstances in view. It is the main object of the present invention to provide an artificial stone flag, which is acid proof, alkali proof, fire proof, water proof, stain-free, light, easy to clean, and durable in use. It is another object of the present invention to provide an artificial stone flag, which is inexpensive to manufacture. To achieve these and other objects of the present invention, the artificial stone flag comprises an artificial stone flag body molded from the mixture of polyester/acrylic resin, densified alumina, catalyst, and hardening agent, and a flexible stuffing material embedded in the artificial stone flag body. The flexible stuffing material can be made of sponge, plastic block, or rubber block. The flexible stuffing material can be made having through holes such that a part of the artificial stone flag body fills up the through holes of the flexible stuffing material during its molding process.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006]FIG. 1A is a schematic drawing showing the formation of an artificial stone flag according to the present invention (Step I).

[0007]FIG. 1B is a schematic drawing showing the formation of an artificial stone flag according to the present invention (Step II).

[0008]FIG. 1C is a schematic drawing showing the formation of an artificial stone flag according to the present invention (Step III).

[0009]FIG. 2 is a sectional view of an artificial stone flag constructed according to the first embodiment of the present invention.

[0010]FIG. 3 is a sectional view of an artificial stone flag constructed according to the second embodiment of the present invention.

[0011]FIG. 4 is a sectional view of an artificial stone flag constructed according to the third embodiment of the present invention.

[0012]FIG. 5 is a sectional view of an artificial stone flag constructed according to the fourth embodiment of the present invention.

[0013]FIG. 6 is a sectional view of an artificial stone flag constructed according to the fifth embodiment of the present invention.

[0014]FIG. 7 is a sectional view of an artificial stone flag constructed according to the sixth embodiment of the present invention.

[0015]FIG. 8 is a sectional view of an artificial stone flag constructed according to the seventh embodiment of the present invention.

[0016]FIG. 9 is a sectional view of an artificial stone flag constructed according to the eighth embodiment of the present invention.

[0017]FIG. 10 is a sectional view of an artificial stone flag constructed according to the ninth embodiment of the present invention.

[0018]FIG. 11 is a sectional view taken along line 11-11 of FIG. 10.

[0019]FIG. 12 is a sectional view of an artificial stone flag constructed according to the tenth embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0020] Referring to FIG. 2, an artificial stone flag according to the first embodiment of the present invention is shown comprising an artificial stone flag body 10 and a stuffing material 20 embedded in the artificial stone flag body 10. The stuffing material 20 is a flexible material obtained from sponge, plastic blocks, or rubber blocks.

[0021] FIGS. 1A˜1C illustrate the molding of the artificial stone flag. A first layer of artificial stone material 11 is obtained from the mixture of polyester/acrylic resin, densified alumina, catalyst, and hardening agent, and then poured in the mold 30 (see FIG. 1A), and then the prepared stuffing material 20 is placed on the first layer of artificial stone material 11 in the mold 30 before hardening of the first layer of artificial stone material 11 (see FIG. 1B), and then a second layer of artificial stone material 11′ is poured in the mold 30 (see FIG. 1C). The second layer of artificial stone material 11′ is also obtained from the mixture of polyester/acrylic resin, densified alumina, catalyst, and hardening agent. When hardened, the molding, namely, the finished artificial stone flag is removed from the mold 30. The stuffing material 20 has through holes 201 (see FIG. 1B). During molding, the second layer of artificial stone material 11′ fills up the through holes 201 (see FIG. 1C). After molding, integrated positioning rods 202 are formed in the artificial stone flag body 10 and extended through the stuffing material 20 (see FIG. 2). When hardening, the first layer of artificial stone material 11 and the second layer of artificial stone material 11′ are contracting, thereby causing the flexible stuffing material 20 to be compressed. Because the stuffing material 20 is compressible, the artificial stone flag does not crack when hardening.

[0022]FIG. 3 shows an artificial stone flag constructed according to the second embodiment of the present invention. According to this embodiment, the artificial stone flag comprises an artificial stone flag body 102, a flexible stuffing material 203 embedded in the artificial stone flag body 102, and a hard stuffing material (for example, wooden material) 40 fitted into the flexible stuffing material 203 and embedded in the artificial stone flat body 102. The flexible stuffing material 203 is a box-like flexible member having four vertical peripheral sidewalls and a horizontal bottom sidewall. The hard stuffing material 40 has through holes 401 respectively coincided with respective through holes 201 of the flexible stuffing material 203. After molding, integrated positioning rods 202 are formed in the artificial stone flag body 102 and extended through the flexible stuffing material 203 and the hard stuffing material 40.

[0023]FIG. 4 shows an artificial stone flag constructed according to the third embodiment of the present invention. According to this embodiment, the artificial stone flag comprises an artificial stone flag body 103, a flexible stuffing material 204 embedded in the artificial stone flag body 103, and a hard stuffing material (for example, wooden material) 402 fitted into the flexible stuffing material 204 and embedded in the artificial stone flat body 103. The flexible stuffing material 204 is shaped like a rectangular tube having four peripheral sides. The hard stuffing material 402 has through holes 401. After molding, integrated positioning rods 202 are formed in the artificial stone flag body 103 and extended through the flexible stuffing material 204 and the hard stuffing material 402.

[0024]FIG. 5 shows an artificial stone flag constructed according to the fourth embodiment of the present invention. According to this embodiment, the artificial stone flag comprises an artificial stone flag body 104, a first flexible stuffing material 203 embedded in the artificial stone flag body 104, a hard stuffing material (for example, wooden material) 403 fitted into the first flexible stuffing material 203 and embedded in the artificial stone flat body 104, and a second flexible stuffing material 206 covered on the first flexible stuffing material 203 and the hard stuffing material 403. The first flexible stuffing material 203 is a box-like flexible member having four vertical peripheral sidewalls and a horizontal bottom sidewall. The hard stuffing material 403 has through holes 401 respectively coincided with resspecve through holes 201 of the first flexible stuffing material 203 and second flexible stuffing material 206. After molding, integrated positioning rods 202 are formed in the artificial stone flag body 104 and extended through the first flexible stuffing material 203, the second flexible stuffing material 206, and the hard stuffing material 403.

[0025] According to the embodiments shown in FIGS. 3˜5, the stuffing materials absorb compressive force during hardening of the artificial stone flag body, preventing cracking of the finished artificial stone flag.

[0026]FIG. 6 shows an artificial stone flag constructed according to the fifth embodiment of the present invention. According to this embodiment, the artificial stone flag comprises an artificial stone flag body 105, a flexible stuffing material 207 and a hard stuffing material 404 embedded in the artificial stone flag body 105 and horizontally arranged side by side. The flexible stuffing material 207 and the hard stuffing material 404 have respective through holes 201;40 for the filling of artificial stone material during molding. After molding, integrated positioning rods 202 are formed in the artificial stone flag body 105 and extended through the flexible stuffing material 207 and the hard stuffing material 404.

[0027]FIG. 7 shows an artificial stone flag constructed according to the sixth embodiment of the present invention. According to this embodiment, the artificial stone flag comprises an artificial stone flag body 106, and a hard stuffing material 405 embedded in the artificial stone flag body 106. The artificial stone flag body 106 comprises a frame base 1061 formed of the first layer of artificial stone material obtained from the mixture of polyester/acrylic resin, densified alumina, catalyst, and hardening agent, and a back panel 50 formed of the second layer of artificial stone material obtained from the mixture of polyester/acrylic resin, densified alumina, catalyst, and hardening agent and covered on the frame base 1061 and the hard stuffing material 405.

[0028]FIG. 8 shows an artificial stone flag constructed according to the seventh embodiment of the present invention. According to this embodiment, the artificial stone flag comprises an artificial stone flag body 107, and a hard stuffing material 405 embedded in the artificial stone flag body 107. The artificial stone flag body 107 comprises a comprised of a frame base 1061 formed of an artificial stone material obtained from the mixture of polyester/acrylic resin, densified alumina, catalyst, and hardening agent, and a back panel 501 formed of thin sheet of wooden material or melamine and covered on the frame base 1061 and the hard stuffing material 405.

[0029]FIG. 9 shows an artificial stone flag constructed according to the eighth embodiment of the present invention. According to this embodiment, the artificial stone flag comprises an artificial stone flag body 108, hard slats 406 embedded in the artificial stone flag body 108 and equally spaced from one another. The artificial stone flag body 108 comprises a comprised of a frame base 1061 formed of an artificial stone material obtained from the mixture of polyester/acrylic resin, densified alumina, catalyst, and hardening agent, and a back panel 501 formed of thin sheet of wooden material or melamine and covered on the frame base 1061 and the hard stuffing material 406.

[0030]FIGS. 10 and 11 show an artificial stone flag constructed according to the ninth embodiment of the present invention. According to this embodiment, the artificial stone flag comprises an artificial stone flag body 109, a plurality of frame-like flexible stuffing materials 208 embedded in the artificial stone flag body 109 and equally spaced from one another, and a plurality of hard stuffing materials 407 respectively fitted into the frame-like flexible stuffing materials 208 and embedded in the artificial stone flag body 109. The hard stuffing materials 407 each have a plurality of through holes 401. After molding, integrated positioning rods 202 are formed in the artificial stone flag body 109 and extended through the flexible stuffing materials 208 and the hard stuffing material 407.

[0031]FIG. 12 shows an artificial stone flag constructed according to the tenth embodiment of the present invention. According to this embodiment, the artificial stone flag comprises an artificial stone flag body 110, a plurality of frame-like flexible stuffing materials 208 embedded in the artificial stone flag body 110 and equally spaced from one another, a plurality of hard stuffing materials 407 respectively fitted into the frame-like flexible stuffing materials 208 and embedded in the artificial stone flag body 110, and a reinforcing support frame 60 embedded in the artificial stone flag body 110 to separate the frame-like flexible stuffing materials 208 from one another and to reinforce the structural strength of the artificial stone flag. Similar to the aforesaid ninth embodiment, the hard stuffing materials 407 of the tenth embodiment each have a plurality of through holes 401. After molding, integrated positioning rods 202 are formed in the artificial stone flag body 110 and extended through the flexible stuffing materials 208 and the hard stuffing material 407.

[0032] A prototype of artificial stone flag has been constructed with the features of FIGS. 1˜12. The artificial stone flag functions smoothly to provide all of the features discussed earlier.

[0033] Although particular embodiments of the invention have been described in detail for purposes of illustration, various modifications and enhancements may be made without departing from the spirit and scope of the invention. Accordingly, the invention is not to be limited except as by the appended claims. 

What the invention claimed is:
 1. An artificial stone flag comprising an artificial stone flag body, and stuffing means embedded in said artificial stone flag body.
 2. The artificial stone flag as claimed in claim 1, wherein said stuffing means comprises a flexible stuffing material.
 3. The artificial stone flag as claimed in claim 2, wherein said flexible stuffing material is made of sponge.
 4. The artificial stone flag as claimed in claim 2, wherein said flexible stuffing material is comprised of at least one plastic block.
 5. The artificial stone flag as claimed in claim 2, wherein said flexible stuffing material is comprised of at least one rubber block.
 6. The artificial stone flag as claimed in claim 1, wherein said stuffing means comprises a flexible stuffing material having a plurality of through holes filled up by a part of said artificial stone flag body.
 7. An artificial stone flag comprising an artificial stone flag body, flexible stuffing means embedded in said artificial stone flag body, and hard stuffing means fitted into said flexible stuffing means and embedded in said artificial stone flag body.
 8. The artificial stone flag as claimed in claim 7, wherein said flexible stuffing means and said hard stuffing means have through holes respectively filled up by a part of said artificial stone flag body.
 9. The artificial stone flag as claimed in claim 8, wherein said flexible stuffing material has four vertical peripheral sidewalls and a horizontal bottom wall; said hard stuffing material is mounted in said flexible stuffing material and surrounded by the four vertical peripheral sidewalls and horizontal bottom wall of said flexible stuffing material.
 10. The artificial stone flag as claimed in claim 8, wherein said flexible stuffing means is shaped like a rectangular tube having four peripheral sidewalls; said hard stuffing means is fitted into said flexible stuffing means and surrounded by the four peripheral sidewalls of said flexible stuffing means inside said artificial stone flag body.
 11. The artificial stone flag as claimed in claim 8, wherein said flexible stuffing material has four vertical peripheral sidewalls a horizontal bottom wall, and a horizontal top wall; said hard stuffing material is mounted in said flexible stuffing material and surrounded by the four vertical peripheral sidewalls, horizontal bottom wall, and horizontal top wall of said flexible stuffing material.
 12. The artificial stone flag as claimed in claim 8, wherein said flexible stuffing means comprises a plurality of hollow flexible stuffing members respectively embedded in said artificial stone flag body and spaced from one another; said hard stuffing means comprises a plurality of hard stuffing members respectively fitted into said hollow flexible stuffing members and embedded in said artificial stone flag body.
 13. The artificial stone flag as claimed in claim 12, further comprising a reinforcing support frame embedded in said artificial stone flag body and separating said flexible stuffing members from one another.
 14. An artificial stone flag comprising a hollow artificial stone flag body defining an opening, hard stuffing means mounted in said hollow artificial stone flag body, and a back panel sealed to the opening of said hollow artificial stone flag body to fixedly secure said hard stuffing means inside said hollow artificial stone flag body.
 15. The artificial stone flag as claimed in claim 14, wherein said hard stuffing means is comprised of a solid wooden block.
 16. The artificial stone flag as claimed in claim 14, wherein said hard stuffing means comprises a plurality of slats.
 17. The artificial stone flag as claimed in claim 14, wherein said back panel is a solid surface material.
 18. The artificial stone flag as claimed in claim 14, wherein said back panel is made of melamine.
 19. The artificial stone flag as claimed in claim 14, wherein said back panel is a thin sheet face member. 